Oscillating multi-tool system

ABSTRACT

An oscillating power tool includes a housing, a motor, a tool holder driven oscillatingly, a flange threadedly coupled to a plunger, and a lever pivotable between a clamping position and a release position. The flange is configured to be movable in an axial direction. The flange is configured to clamp the output element onto the tool holder in the clamping position and configured to be displaced a first distance from the tool holder in the release position. The lever includes a cam surface including a substantially flat surface configured to engage the plunger in the release position. In the release position, a gap is disposed between the lever and the housing to allow the lever to be rotated past the release position. The lever is configured to displace the flange a second distance from the tool holder, larger than the first distance, when rotated past the release position.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/162,823, filed Jan. 29, 2021, which is a continuation of U.S. patentapplication Ser. No. 16/200,111, filed Nov. 26, 2018, which is acontinuation of U.S. patent application Ser. No. 15/413,815, filed Jan.24, 2017, now U.S. Pat. No. 10,137,592, which is a continuation of U.S.patent application Ser. No. 14/270,560, filed May 6, 2014, now U.S. Pat.No. 9,555,554, which claims priority to U.S. Provisional PatentApplication No. 61/820,018 filed on May 6, 2013, the entire contents ofall of which are incorporated herein by reference.

BACKGROUND

The present invention relates to power tools driven by an electricmotor. Power tools utilize the rotation of a motor to provide usefultorque for operations such as cutting, sanding, grinding, removingmaterial, drilling, driving fasteners, and the like. For example, theinvention relates to an oscillating power tool.

Oscillating power tools can be utilized with various accessories, suchas blades and sanding or grinding pad attachments, for performingdifferent functions. For example, a plunge cut blade may be attached tothe output, or tool holder, of the oscillating tool to perform a plungecut. Then, a user may remove the plunge cut blade and attach a sandingpad to the tool holder for performing a sanding operation.Conventionally, the accessories can be interchanged by inserting andremoving a fastener, such as a screw, which may be tightened with atool, such as a hex key, to provide a clamping force to secure theaccessory to the tool holder.

SUMMARY

In one aspect, the invention provides an oscillating power tool. Theoscillating power tool includes a housing, a motor disposed within thehousing, a tool holder configured to be driven oscillatingly about anoutput axis by the motor, and a flange configured to clamp an outputelement onto the tool holder. The flange is configured to be movable inan axial direction defined by the output axis. The oscillating powertool also includes a plunger operably coupled for movement with theflange in the axial direction. The plunger and the flange are threadedlycoupled to each other. The oscillating power tool also includes a leverconfigured to actuate the flange, the lever being pivotable between aclamping position and a release position. The flange is configured toclamp the output element onto the tool holder in the clamping position,and the flange is configured to be displaced a first distance from thetool holder in the release position. The lever includes a cam surfaceincluding a substantially flat surface, the substantially flat surfaceconfigured to engage the plunger in the release position. In the releaseposition, a gap is disposed between the lever and the housing to allowthe lever to be rotated past the release position. The lever isconfigured to displace the flange a second distance from the tool holderwhen rotated past the release position. The second distance is largerthan the first distance.

In another aspect, the invention provides an oscillating power toolincluding a housing, a motor disposed within the housing, a tool holderconfigured to be driven oscillatingly about an output axis by the motor,and a flange configured to clamp an output element onto the tool holder.The flange is configured to be movable in an axial direction defined bythe output axis. The oscillating power tool also includes a springconfigured to provide a clamping force for clamping the output element,a plunger operably coupled for movement with the flange in the axialdirection, and a lever configured to actuate the flange. The lever ispivotable between a clamping position and a release position. The flangeis configured to clamp the output element onto the tool holder in theclamping position. The flange is configured to be displaced a firstdistance from the tool holder in the release position. The clampingforce is at least partially relieved in the release position. The leverincludes a cam surface including a substantially flat surface, thesubstantially flat surface configured to engage the plunger in therelease position. The lever is configured to rest in the releaseposition. In the release position, a gap is disposed between the leverand the housing to allow the lever to be rotated past the releaseposition. The lever is configured to further relieve the clamping forcewhen rotated past the release position.

In another aspect, the invention provides an oscillating power toolincluding a housing, a motor disposed within the housing, a tool holderconfigured to be driven oscillatingly about an output axis by the motor,and a flange configured to clamp an output element onto the tool holder.The flange is configured to be movable in an axial direction defined bythe output axis. The oscillating power tool also includes a springconfigured to provide a clamping force for clamping the output element,a plunger operably coupled for movement with the flange in the axialdirection, and a lever configured to actuate the flange, the lever beingpivotable between a clamping position and a release position. The flangeis configured to clamp the output element onto the tool holder in theclamping position. The flange is configured to be displaced a firstdistance from the tool holder in the release position. The clampingforce is at least partially relieved in the release position. The leverincludes a cam surface defining a detent such that the lever isconfigured to rest in the release position by way of the detent. In therelease position, a gap is disposed between the lever and the housing toallow the lever to be rotated past the release position. The lever isconfigured to further relieve the clamping force when rotated past therelease position.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a power tool according to oneconstruction of the invention.

FIG. 2 is a bottom perspective view of a portion of the power tool ofFIG. 1 .

FIG. 3 is a cross section view of a portion of the power tool shown inFIG. 1 .

FIG. 4 is a perspective view of a lever, which is a portion of the powertool of FIG. 1 .

FIG. 5 is a cross section view illustrating a clamping mechanism of thepower tool of FIG. 1 , the clamping mechanism shown in a clampingposition.

FIG. 6 is a cross section view illustrating the clamping mechanism ofthe power tool of FIG. 1 , the clamping mechanism shown in a releaseposition and having a clamp shaft removed.

FIG. 7 is a cross section view illustrating the clamping mechanism ofthe power tool of FIG. 1 , the clamping mechanism shown in a clampingposition and having a blade attached thereto.

FIG. 8 is a cross section view illustrating the clamping mechanism ofthe power tool of FIG. 1 , the clamping mechanism shown in a releaseposition and having the blade attached thereto.

FIG. 9 is a side view of a cam portion of the lever shown in FIG. 4 .

FIG. 10 is a top view of the cam portion of FIG. 9 .

FIG. 11 is a rear view of the cam portion of FIG. 9 .

FIG. 12 is a bottom view of a tool holder of the power tool shown inFIG. 1 .

FIG. 13 is a cross section view of a portion of the tool holder takenalong line 13-13 in FIG. 12 .

FIG. 14 is a cross section view of a portion of the tool holder takenalong line 14-14 in FIG. 12 .

FIG. 15 is a side view of the tool holder of FIG. 12 .

FIG. 16 is a cross section view of the tool holder taken along brokenline 16-16 in FIG. 12 .

FIG. 17 is a bottom perspective view of an adapter for use with thepower tool of FIG. 1 .

FIG. 18 is a bottom view of the adapter of FIG. 17 .

FIG. 19 is a cross section view of a portion of the adapter taken alongline 19-19 in FIG. 18 .

FIG. 20 is a cross section view of a portion of the adapter taken alongline 20-20 in FIG. 18 .

FIG. 21 is a top perspective view of the adapter of FIG. 17 .

FIG. 22 is a top view of the adapter of FIG. 17 .

FIG. 23 is a front view of the adapter of FIG. 17 .

FIG. 24 is a side view of a portion of the power tool of FIG. 1 showingthe adapter of FIG. 17 installed with one surface facing the toolholder.

FIG. 25 is a side view of a portion of the power tool of FIG. 1 showingthe adapter of FIG. 17 installed with an opposite surface facing thetool holder.

FIG. 26 is a cross-sectional view of a portion of the power tool of FIG.1 .

FIG. 27 is a perspective view of a motor of the power tool of FIG. 1 .

FIG. 28 is a perspective view of a motor plate of a motor mount assemblyfor use with the motor of FIG. 27 .

FIG. 29 is a perspective cross section view of the motor plate connectedto the motor.

FIG. 30 is a perspective cross section view of the motor mount assemblyconnected to the motor.

FIG. 31 is a perspective view of an eccentric shaft of the motor mountassembly.

FIG. 32 is a perspective view an accessory for use with the power toolof FIG. 1 .

FIG. 33 is a top perspective view of the accessory FIG. 32 .

FIG. 34 is a top perspective view of the accessory FIG. 32 .

FIG. 35 is a bottom perspective view of the accessory of FIG. 32 .

FIG. 36 is a bottom perspective view of the accessory of FIG. 32including a seal member.

FIG. 37 is a side view of the accessory of FIG. 32 .

FIG. 38-41 are perspective views of another accessory for use with thepower tool of FIG. 1 .

FIG. 42 is a perspective view of yet another accessory for use with thepower tool of FIG. 1 .

FIG. 43 is a perspective view of the accessory of FIG. 42 .

FIG. 44 is a top view of the accessory of FIG. 42 .

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it should be understood thatthe phraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-44 illustrate power tool 10, such as an oscillating tool,according to one construction of the invention. With reference to FIGS.1-3 , the power tool 10 includes a housing 12, a motor 14, a drivemechanism 16, an output element 18, a clamping mechanism 20, and a powersource 22, such as a battery pack, for powering the motor 14. In theillustrated construction, the motor 14 is an electric motor. In otherconstructions, the motor 14 may be pneumatically powered by compressedair passing through a pneumatic motor. In some constructions, a variablespeed or multi-speed motor may be employed. In other constructions, thepower tool 10 may be powered by an AC power source by way of a cord (notshown). In other constructions, other suitable motors and power sourcesmay be employed.

The housing 12 includes two clamshell halves 24 a, 24 b that are coupledtogether to enclose the motor 14 and the drive mechanism 16. Whenconnected together, the clamshell halves 24 a, 24 b define a handleportion 26 and a battery support portion 28 of the housing 12. Thehandle portion 26 is configured to be grasped by a user during operationof the power tool 10. An actuator 30 is coupled with the handle portion26 of the housing 12 for switching the motor 14 between an on (i.e.,energized) position and an off position. In some constructions, aseparate actuator may be employed for changing the motor speed. In otherconstructions, the actuator 30 may additionally be operable to switchthe motor 14 between various speeds of operation. In the illustratedconstruction, the actuator 30 is a sliding actuator that is slideablewith respect to the housing 12 in a direction generally parallel to alongitudinal axis A of the handle portion 26. In other constructions,the actuator 30 may be moveable in other directions and may have otherconfigurations, such as a trigger-style actuator, a depressible button,a lever, a rotating actuator, a paddle actuator, etc. The batterysupport portion 28 is configured to support the battery pack 22 on thehousing 12.

The battery pack 22 is connected to the battery support portion 28 ofthe housing 12 and electrically coupled to the motor 14. Duringoperation of the power tool 10, the battery pack 22 supplies power tothe motor 14 to energize the motor. In the illustrated construction, thebattery pack 22 is a slide-on-style battery pack that includes twoparallel, spaced apart rails (not shown). The rails engage correspondinggrooves (not shown) on another part of the power tool 10 to support thebattery pack 22 on the housing 12. In other embodiments, the batterypack 22 may be a tower-style battery pack that is at least partiallyinserted into the housing 12. The illustrated battery pack 22 is an18-volt Li-ion power tool battery pack. In other embodiments, thebattery pack 22 may have different voltages (e.g., 12 volts, 14.4 volts,28 volts etc.) and/or chemistries (e.g., NiCd, NiMH, etc.).

The motor 14 and the drive mechanism 16 are positioned substantiallywithin the housing 12 in front of the handle portion 26. In someembodiments, the drive mechanism 16 may be positioned within a gear case32 inside of and/or supported by the housing 12. The motor 14 includes adrive shaft 34. The drive mechanism 16 is coupled to the motor 14 to bedriven by the motor 14 by way of the drive shaft 34. The drive mechanism16 converts rotational motion of the drive shaft 34 into oscillatingmotion of the output element 18 rotationally about an axis. In otherconstructions, the power tool may have a drive mechanism that rotates,reciprocates, or imparts an orbital motion to the output element 18.

The output element 18 is coupled to an output shaft, or spindle 36, ofthe drive mechanism 16. The illustrated output element 18 is located atan opposite end of the housing 12 from the battery pack 22, but mayalternatively be located in other locations on the housing 12 relativeto the battery pack 22. In the illustrated construction, the spindle 36defines an output axis B substantially perpendicular to the longitudinalaxis A. When energized, the motor 14 drives the drive mechanism 16 tooscillate the spindle 36 and the output element 18. In the illustratedconstruction, the output element 18 is a cutting blade that isoscillated during operation of the power tool 10. In otherconstructions, the output element 18 may be a different type of bladesuch as a scraper blade, a circular blade, a semi-circular blade, etc.,or a different type of element such as a sanding pad, a grindingelement, etc.

The clamping mechanism 20 clamps the output element 18 to the spindle36. In the illustrated construction, the clamping mechanism 20 is atool-less clamping mechanism that allows a user to attach, remove, andexchange output elements without the use of a tool (toollessly). Theclamping mechanism 20 includes the spindle 36, a plunger 38, a spring40, a tool holder 42, and a clamp shaft 44, which will be described ingreater detail below. A lever 46 is actutable by a user to operate theclamping mechanism 20.

The lever 46 is pivotable about a pin 48, which defines a pivot axis C,between a clamping position (FIGS. 3, 5, and 7 ) and a release position(FIGS. 6 and 8 ). In the clamping position, the output element 18 issecured, or clamped, to the tool holder 42. In the release position, theclamp shaft 44 may be removed such that the output element 18 may beremoved or exchanged, as will be described in greater detail below. Thelever 46 includes a cam 50 for displacing the plunger 38. In theclamping position, the cam 50 does not engage the plunger 38. In therelease position, the cam 50 engages the plunger 38 to displace theplunger 38, as will be described in greater detail below.

As illustrated in FIGS. 4 and 9-11 , the cam 50 includes a cam surface52 having radii at surface points P0-P13 on the cam surface 52. Theradii range from about 5.35 mm (0.211 in.) at surface point P0 to about8.85 mm (0.348 in.) at surface point P13. The cam surface 52 betweensurface points P0 and P13 extends about 195 degrees about the pivot axisC. Table 1 below provides the radius and angle of each surface point P0through P13. Surface points P0 and P1 are disposed on a firstsubstantially flat surface 54 of the cam 50. In the clamping position,surface points P0 and P1 are located adjacent the plunger 38 and do notengage the plunger 38. As the lever 46 is rotated from the clampingposition to the release position, the cam surface 52 begins to engagethe plunger 38 and then to displace the plunger 38. The lever 46 rotatesabout 170 degrees between the clamping position and the releaseposition. Between surface points P11 and P13, (e.g., at or near surfacepoint P11 or P12), the cam surface 52 flattens into a secondsubstantially flat surface 56, which provides a detent 58 duringmovement of the lever 46. When the lever 46 is in the release position,the lever 46 rests at or after the detent 58 because the radius beforeand after the detent 58 is greater than the radius at the detent 58 (seeradius measurements of the surface points P11-P13 in Table 1),inhibiting movement of the lever 46 out of the release position.

TABLE 1 Surface Position Angle (degrees) Radius (mm) Radius (in.) P0 15.347 0.211 P1 15 5.535 0.218 P2 30 5.915 0.233 P3 45 6.293 0.248 P4 606.665 0.262 P5 75 6.962 0.274 P6 90 7.211 0.284 P7 105 7.447 0.293 P8120 7.673 0.302 P9 135 7.889 0.311 P10 150 8.164 0.321 P11 165 8.5020.335 P12 180 8.487 0.334 P13 195 8.845 0.348

In the release position (FIGS. 6 and 8 ), a gap 60 remains between thelever 46 and the housing 12 to allow the lever 46 to be rotated past thedetent 58 (e.g., to travel more than 170 degrees). Rotating the lever 46past the detent 58 further displaces the plunger 38 in the event thatextra plunger displacement is needed to assist with releasing the outputelement 18. For example, at surface point P13, the radius is about 8.85mm (0.348 in.), which is greater than the radius at the release position(at or near surface point P11 or P12), which is about 8.48 mm (0.334in.) Thus, rotating the lever 46 past the detent 58 further displacesthe plunger 38. However, a user must hold the lever 46 past the detent58 to maintain the lever 46 past the release position as the lever 46 isbiased to the release position when the lever 46 is past the releaseposition.

The clamping mechanism 20 includes the spindle 36, the plunger 38, thespring 40, the tool holder 42, and the clamp shaft 44. In theillustrated construction, the spindle 36 is journalled to the gear case32 by way of a needle bearing 62 and a rear bearing 64 to allow thespindle 36 to oscillate with respect to the gear case 32. Furthermore,the needle bearing 62 is press fit to the gear case 32, the rear bearing64 is press fit to the gear case 32, the tool holder 42 is press fit toan intermediate member 43, which is press fit to the spindle 36, and aportion of the drive mechanism 16 (e.g., a fork which will be describedin greater detail below) is press fit to the spindle 36. In otherconstructions, the components of the clamping mechanism 20 may becoupled or fastened in other suitable ways.

The clamping mechanism 20 also includes an upper shoulder 66 and a lowershoulder 68 (FIG. 3 ) that are generally disposed inside the spindle 36,which is hollow. In the illustrated construction, the upper shoulder 66is formed on an inner surface of the spindle 36 and the lower shoulder68 is formed on an inner surface of the intermediate member 43. In otherconstructions, the upper and lower shoulders 66, 68 may be formed withother components of the clamping mechanism 20. In other constructions,the tool holder 42 and the intermediate member 43 may be formed as asingle piece.

The plunger 38 includes a plunger shoulder 70, configured as a flange inthe illustrated construction, which is disposed adjacent the uppershoulder 66. The spring 40 is disposed between and engages the lowershoulder 68 (e.g., the tool holder) and the plunger shoulder 70 (e.g.,the plunger 38). The plunger 38 includes a threaded bore 72, whichreceives the clamp shaft 44.

The clamp shaft 44 includes a threaded shaft 74, which is threadablyreceived in the threaded bore 72 of the plunger 38. The threaded shaft74 is configured as a double lead screw (e.g., having two threadsinstead of a single thread) such that half as many turns are required toadvance the clamp shaft 44 a given distance as with a single lead screw.The threaded shaft 74 has a sufficient coefficient of friction so as tobe self-locking.

The clamp shaft 44 is fixedly coupled to a flange 75 having a face 76for engaging the output element 18 to apply a clamping force to theoutput element 18. The flange 75 includes a tab 78 for finger tighteningthe clamp shaft 44 onto the threaded bore 72 of the plunger 38 by way ofthe threaded engagement therebetween. The tab 78 projects from theflange 75 and provides opposing surfaces 80 opposed about an axis ofrotation (which coincides with output axis B) and engageable by a userto rotate and tighten or loosen the clamp shaft 44. The opposingsurfaces are substantially planar and extend in planes substantiallyparallel to the output axis B. The tab 78 projects from the flange 75substantially from a diameter defined by the flange 75. The tab 78 alsoincludes a slot 82 sized to receive a tool (e.g., a flat headscrewdriver or an output element 18) for further tightening or looseningof the clamp shaft 44 if desired.

In the clamping position, the spring 40 provides the clamping force thatholds the output element 18 between the face 76 of the clamp shaft 44and the tool holder 42 tightly. In the illustrated construction, thespring 40 is a compression spring formed into a cylindrical shape fromround music wire having a diameter of about 0.16 inches. The springmaterial is preferably shot peened and is preset. Preferably, the spring40 has a spring rate of about 1300 lbf/in and provides about 275 lbs ofclamping force. In other constructions, other types of springs havingother materials, configurations, shapes, and properties may be employed.

In the clamping position (FIGS. 3, 4 and 6 ), the lever 46 does notengage the plunger 38 so that the clamping mechanism 20 can oscillatefreely while the motor 14 is energized without friction between theplunger 38 and the lever 46. Furthermore, the spring 40 is compressedbetween the plunger shoulder 70 and the lower shoulder 68 to provide theclamping force. The lower shoulder 68 of the tool holder 42 is fixedsuch that the clamping force of the spring 40 acts to displace theplunger 38 towards the cam 50. In turn, the clamp shaft 44 is fixed tothe plunger 38 (by way of the self-locking threaded engagement describedabove) such that the clamping force of the spring 40 acts to displacethe face 76 of the flange 75 towards the tool holder 42 (FIG. 4 ). Whenthe output element 18 is installed between the face 76 of the flange 75and the tool holder 42 and the lever 46 is in the clamping position, theface 76 of the flange 75 engages a face 47 (FIG. 16 ) of the outputelement 18 to apply the clamping force so that the output element 18 isclamped between the flange 75 and the tool holder 42 by the clampingforce of the spring (FIGS. 3 and 6 ).

In the release position (FIGS. 6 and 8 ), the lever 46 engages theplunger 38 (as described in greater detail above) to displace theplunger 38 away from the lever 46. The lever 46 rests at the detent 58,thereby relieving the clamping force from the output element 18. Whilethe lever 46 is in the release position, or while the user holds thelever 46 past the release position (as described above), the user mayloosen and remove the clamp shaft 44 from the plunger 68 by grasping theopposing surfaces 80 of the tab 78 by hand or with the use of a tool inthe slot 82, if desired, to apply a torque to the clamp shaft 44. Whenthe clamp shaft 44 is removed, the output element 18 may be removed andreplaced, if desired. Then, the clamp shaft 44 may be hand-tightened (ortightened by a tool, if desired) into the threaded bore 72 of theplunger 38 and the lever 46 returned to the clamping position to returnthe clamping force onto the tool holder 42.

As illustrated in FIGS. 12-16 , the tool holder 42 includes taperedlocating features 84 (some or all of which are substantially identical)projecting from an outer surface 86 of the tool holder 42 for engagingthe output element 18. The locating features 84 are received byapertures 85 (FIG. 16 ) in the output element 18. In the illustratedconstruction, the tool holder 42 includes eight locating features 84spaced angularly on the outer surface 86 in four groups of two insubstantially a circle about the output axis B. The locating features 84in a group of two are spaced from each other by an angle D of about 30degrees. Each of the four groups of two locating features 84 is spacedfrom an adjacent group of two locating features 84 by an angle E ofabout 60 degrees. The flange 75 is disposed substantially within thecircle defined by the radial distance of the locating features 84. Thelocating features 84 are diametrically opposed from each other by adistance F of about 25.5 mm (1.00 in.) Each locating feature 84 istapered to provide substantially a zero-clearance fit with the apertures85 in the output element 18 (as shown in FIG. 16 ) in at least acircumferential direction so as to transfer oscillating motion to theoutput element 18 without substantial losses or wiggling therebetween.Each locating feature 84 has a base width G of about 2.20 mm (0.0866in.) and a top width H of about 0.90 mm (0.035 in.) The base width ispreferably greater than about 0.075 inches and less than about 0.095inches. The base width G is defined as the shortest distance from thefirst sidewall to the second sidewall at a base 51 (FIG. 15 ) of thelocating feature 84, i.e., the distance from the first sidewall to thesecond sidewall at the base 51 that is tangential to a circumferentialor angular arc (e.g., the circle discussed above) about the output axisB. The base 51 of the locating feature 84 is defined where the locatingfeature 84 substantially meets a plane defined by the outer surface 86of the tool holder 42.

At least some of the apertures 85 have a width G1 that corresponds witha respective base width G of the locating feature 84 with which it ismated in the clamping position, as illustrated in FIG. 16 . In theillustrated construction, the width G1 is about 1.9 mm (0.075 in.) Inother constructions, the width G1 may be between about 1.0 mm (0.039in.) and about 2.19 mm (0.0862 in.) Preferably, the width G1 is betweenabout 1.7 mm (0.067 in.) and about 2.1 mm (0.083 in.) The width G1 issubstantially smaller than the base with G such that a face 49 of theoutput element 18 facing the outer surface 86 of the tool holder 42 isoffset from the outer surface 86 of the tool holder 42 by a gap 122,which will be described in greater detail below. Therefore, in otherconstructions in which the locating features 84 on the tool holder 42have other sizes, dimensions, and shapes, the size of the width G1 maybe adapted to be substantially smaller than the base width G of thelocating features 84 to achieve a similar fit and the gap 122.

FIG. 13 illustrates a cross section through one of the locating features84 showing the taper in the circumferential direction. The locatingfeature 84 has a circumferential taper angle J of about 28 degreesincluded between circumferential sidewalls 88 such that acircumferential sidewall has an angle K with respect to the outersurface 86 of about 104 degrees. The sidewalls 88 are tapered becausethe angle K is greater than 90 degrees. In some constructions, the angleK is greater than or less than 104 degrees, but greater than 90 degrees.Preferably, the angle K is between about 100 degrees and about 109degrees. The locating feature 84 has a bottom radius R1 of about 0.20 mm(0.0079 in.) and a top radius R2 of about 0.20 mm (0.0079 in.) In otherconstructions, the top radius R2 may be replaced with a flat corner(e.g., as illustrated in FIG. 19 , which will be described in greaterdetail below). In the illustrated construction, the locating feature 84is sunken with respect to the outer surface 86 by a distance M of about0.20 mm (0.0079 in.) In other constructions, the locating feature 84need not be sunken with respect to the outer surface 86 and may be flushwith the outer surface 86. In the illustrated construction, the locatingfeatures 84 are substantially tapered from the base 51 to the top radiusR2. In other constructions, the locating features 84 may be onlypartially tapered from base to tip.

FIG. 14 illustrates a cross section through one of the locating features84 showing the taper in a radial direction. In the illustratedconstruction, the locating feature 84 is substantially not tapered inthe radial direction such that radial sidewalls 89 are substantiallyparallel and have an angle N with respect to the outer surface 86 ofabout 90 degrees. Essentially, the locating feature 84 is not tapered inthe radial direction; however, in other constructions, the locatingfeature 84 may be tapered in the radial direction (e.g., such that theangle N is greater than 90 degrees) as well as the circumferentialdirection. FIG. 14 also illustrates a height P of the locating feature84, which is about 2.0 mm (0.079 in.) with respect to the outer surface86. The locating feature 84 has a length Q of about 2.35 mm (0.0925 in.)Thus the overall shape of each locating feature 84 is substantially atruncated pyramid.

As illustrated in FIGS. 12 and 15 , the tool holder 42 also includesfour radial grooves 90 spaced from each adjacent radial groove 90 by anangle S of about 90 degrees. Each radial groove 90 has a recessed base91 with a base width T of about 2.26 mm (0.0890 in.), a depth U of about1.80 mm (0.0709 in.) from the outer surface 86, and is tapered inwardsby a taper angle V of about 85 degrees with respect to the outer surface86.

As illustrated in FIG. 16 , the output element 18 is fully engaged withthe tool holder 42. The output element 18 is fully engaged with the toolholder 42 when the locating features 84 are fully received in theapertures 85, i.e., when the output element 18 is wedged onto thelocating features 84 such that the locating features 84 are received bythe apertures 85 and the output element 18 is inhibited from movingcloser to the outer surface 86 by the increased base width G of thelocating feature 84 with respect to the corresponding width G1 of theaperture 85 of the output element 18. When the output element 18 isfully received, the output element 18 substantially does not engage thebases 51 of the locating features 84. When the clamping force is atleast partially applied to the output element 18, the clamping force isallocated towards more tightly holding the output element 18 on the toolholder 42. By way of the increased base width G of the locating feature84 with respect to the corresponding width G1 of the aperture 85 of theoutput element 18, it is ensured that the output element 18 is securelyengaged in a driving relationship with the tool holder 42, e.g., byminimizing losses such as wiggle or vibrations when the tool holder 42drives the output element 18, without the need for the added clampingforce of a tool-tightened fastener. Thus, the invention provides a toolholder capable of securely driving an output element with only theclamping force of a toolless clamping mechanism (e.g., the clampingforce of a spring).

As shown in FIGS. 17-23 , the power tool 10 also includes a two-sidedadapter 92 for mating with the tool holder 42 to provide differentlocating features for receiving output elements 18 having differentapertures. The adapter 92 includes a first side (FIGS. 17-20 ) having afirst surface 100 and a second side (FIGS. 21-22 ) having a secondsurface 108. The adapter 92 includes eight apertures 94. In theillustrated construction, the apertures 94 are slots extending radiallyinward from an outer edge 96 for receiving the locating features 84 ofthe tool holder 42 and for providing a substantially zero-clearance fitwith the locating features 84 of the tool holder 42. In otherconstructions, the apertures may be configured as recesses, cavities,holes, openings, etc. The apertures 94 correspond with the size andspacing of the locating features 84 of the tool holder 42 and eachincludes a pair of substantially parallel side walls 93 defining theaperture 94. The pair of side walls 93 are spaced apart from each otherby a width QQ of about 1.9 mm (0.075 in.) (FIGS. 14 and 18 ).

Each of the apertures 94 also includes a radius R3. The radius R3 islocated between each side wall 93 and the respective adjacent surface(i.e., the first surface 100 or the second surface 108) on both sides ofthe adapter 92. In the illustrated construction, the radius R3 is about0.24 mm (0.0094 in.) and in other constructions may be between about0.20 mm (0.0079 in.) and about 0.30 mm (0.012 in.) The radii R3 aresized and spaced from each other across the aperture 94 specifically tofit the locating features 84. In other constructions in which thelocating features 84 on the tool holder 42 have other sizes and shapes,the size of the radius R3 and the width QQ between radii R3 may beadapted to fit the locating features 84. The adapter 92 also includes acentral aperture 98 for receiving the clamp shaft 44.

The tool holder 42 is fully engaged with the adapter 92 when thelocating features 84 are fully received in the apertures 94, i.e., whenthe adapter 92 is wedged onto the locating features 84 such that thelocating features 84 are received by the apertures 94 and the adapter 92is inhibited from moving closer to the outer surface 86 by the increasedbase width G of the locating feature 84 with respect to thecorresponding width QQ of the aperture 94 of the adapter 92. When theadapter 92 is fully received, the adapter 92 substantially does notengage the bases 51 of the locating features 84. In the illustratedconstruction, the adapter 92 may be fully received by the locatingfeatures 84 when the adapter is flipped with either the first surface100 facing the tool holder 42 (FIG. 24 ) or the second surface 108facing the tool holder 42 (FIG. 25 ). Thus, the adapter 92 has thesubstantially zero-clearance fit with the tool holder 42 and is fullyengaged with the tool holder 42 (as described above), with the gap 122present between the first surface 100 (or the second surface 108) andthe outer surface 86 of the tool holder 42 in a similar manner asdescribed above with respect to the output element 18 being installed onthe tool holder 42 or on the adapter 92.

FIG. 18 illustrates the first side of the adapter having the firstsurface 100. The first side includes four raised locating features 102spaced evenly about a center of the adapter (i.e., about 90 degreesapart). Each locating feature 102 has a base width W of about 2.27 mm(0.0894 in.) and a top width X of about 1.26 mm (0.0496 in.) Thelocating features 102 are diametrically opposed from each other by adistance Y of about 19.34 mm (0.7614 in.) Each locating feature 102 istapered to provide substantially a zero-clearance fit with and fullyengage (leaving the gap 122 as described above) the output element 18 ina similar manner as described above with respect to the locatingfeatures 84. Thus, the adapter 92 is essentially an extension of thetool holder 42 that provides a different size, shape, or arrangement oflocating features 102 and may be defined as being a part of the toolholder 42 when attached to the tool holder 42. The taper providessubstantially a zero-clearance fit in full engagement (as describedabove) with the output element 18 so as to transfer oscillating motionto the output element 18 without substantial gaps or wobblingtherebetween, while leaving the gap 122 as described above.

In the illustrated construction, when the adapter is flipped such thatthe first surface 100 faces the tool holder 42, the locating features102 do not substantially engage the tapered groove 90 of the tool holder42, but may be partially received in the tapered groove 90 withoutcontacting the recessed base 91 of the groove 90. However, in otherconstructions, the locating features 102 of the adapter 92 are fullyreceived in and engage with the tapered groove 90 such that the adapter92 is inhibited from moving closer to the tool holder 42 because thetapered groove 90 narrows towards the recessed base 91 having the basewidth T. In such constructions, the locating features 102 are engaged inthe tapered groove 90 in the tool holder 42 without contacting therecessed base 91 of the groove 90. Thus, the locating features 102 havethe substantially zero-clearance fit with the tool holder 42 and arefully engaged with the tool holder 42 (as described above), with the gap122 present between the first surface 100 and the outer surface 86 ofthe tool holder 42 in a similar manner as described above with respectto the output element 18 being installed on the tool holder 42 or on theadapter 92. As such, in the illustrated construction, the substantiallyzero-clearance fit is achieved by the engagement between the locatingfeatures 84 of the tool holder 42 and the apertures 94 in the adapter92. However, in some constructions, the substantially zero-clearance fitis alternatively or additionally achieved by an engagement between thelocating features 102 of the adapter 92 and the tapered groove 90 in thetool holder, as described above.

FIG. 19 illustrates a cross section through one of the locating features102 showing the taper in the circumferential direction. The locatingfeature 102 has a circumferential taper angle Z of about 36 degreesincluded between circumferential sidewalls 104 such that acircumferential sidewall 104 has an angle AA with respect to the firstsurface 100 of about 108 degrees. In some constructions, the locatingfeature 102 is sunken with respect to the first surface 100 by adistance of about 0.25 mm (0.0098 in.) (similar to the locating feature84 being sunken with respect to the outer surface 86 by the distance Mas shown in FIG. 14 ). In the illustrated construction, the locatingfeature 102 need not be sunken and is flush with the first surface 100.

FIG. 20 illustrates a cross section through one of the locating features102 showing the taper in a radial direction. In the illustratedconstruction, the locating feature 102 is substantially not tapered inthe radial direction such that a radial sidewall 106 has an angle CCwith respect to the first surface 100 of about 90 degrees. Essentially,the locating feature 102 is not tapered in the radial direction;however, in other constructions, the locating feature 102 may be taperedin the radial direction (e.g., such that the angle CC is greater than 90degrees) as well as the circumferential direction. FIG. 16 alsoillustrates a height DD of the locating feature, which is about 1.5 mm(0.059 in.) with respect to the first surface 100. The locating feature102 has a length EE of about 2.35 mm (0.0925 in.)

FIGS. 21-22 illustrate the second side of the adapter 92. The secondside has the second surface 108 substantially parallel to the firstsurface 100 and spaced therefrom by a distance FF of about 2.5 mm (0.098in.) (FIG. 23 ). The second side includes a locating feature 110 havingfour radially extending arms 112 evenly spaced with respect to eachother (i.e., about 90 degrees apart). Each arm 112 has a base width GGof about 2.97 mm (0.117 in.) and a distal width HH of about 1.34 mm(0.0528 in.) The distal ends of the arms 112 are diametrically opposedfrom each other by a distance JJ of about 14.44 mm (0.569 in.) Each arm112 is tapered in at least the circumferential direction (FIG. 23 )located at the corners of a distal end of the arm 94. The taper providessubstantially a zero-clearance fit in full engagement (as describedabove) with the output element 18 so as to transfer oscillating motionto the output element 18 without substantial gaps or wobblingtherebetween, while leaving the gap 122, as described above, in asimilar manner as described above with respect to the locating features84. Thus, the adapter 92 is essentially an extension of the tool holder42 that provides a different size, shape, or arrangement of locatingfeature 110 and may be defined as being a part of the tool holder 42when attached to the tool holder 42.

In the illustrated construction, when the adapter 92 is flipped suchthat the second surface 108 faces the tool holder 42, the locatingfeature 110 does not substantially engage the tapered groove 90 of thetool holder 42, but may be partially received in the tapered groove 90without contacting the recessed base 91 of the groove 90. However, inother constructions, the locating feature 110 of the adapter 92 is fullyreceived and engaged in the tapered groove 90 such that the adapter 92is inhibited from moving closer to the tool holder 42 because thetapered groove 90 narrows towards the recessed base 91 having the basewidth T. In such constructions, the locating feature 110 is received inthe tapered groove 90 in the tool holder 42 without contacting therecessed base 91 of the groove 90. Thus, the locating feature 110 hasthe substantially zero-clearance fit with the tool holder 42 and isfully engaged with the tool holder 42 (as described above), with the gap122 present between the second surface 108 and the outer surface 86 ofthe tool holder 42 in a similar manner as described above with respectto the output element 18 being installed on the tool holder 42 or on theadapter 92. As such, in the illustrated construction, the substantiallyzero-clearance fit is achieved by the engagement between the locatingfeatures 84 of the tool holder 42 and the apertures 94 in the adapter92. However, in some constructions, the substantially zero-clearance fitis alternatively or additionally achieved by an engagement between thelocating feature 110 of the adapter 92 and the tapered groove 90 in thetool holder, as described above.

FIG. 23 illustrates the taper angle KK of the distal end 95 of the arm112 is about 112 degrees with respect to the second surface 108 and thetaper angle LL of the sides of the arm 112 is about 106 degrees withrespect to the second surface 108. A height X of the locating feature110 is about 1.5 mm (0.059 in.) and the locating feature 110 includes anon-tapered portion having a height MM of about 0.5 mm (0.020 in.)

The power tool 10 also includes a light emitting diode (LED) 114 (FIG. 3) disposed in a front of the housing 12 adjacent the rear bearing 64 inthe direction of longitudinal axis A. The LED 114 is angled downwardtoward the output member 18 so as to provide useful lighting in thevicinity of the workpiece. A lens 116 covers the LED 114 to diffuse thelight.

FIG. 26 illustrates a motor mount assembly 200 for the motor 14 of thepower tool 10. The motor mount assembly 200 connects to an axial face204 of a motor can 208 to mount the motor 14 within the housing 12. Theassembly 200 secures the motor 14 axially, radially, and laterally toinhibit the motor 14 from sliding, rotating/spinning, orwobbling/pitching relative to the housing 12 during operation of thepower tool 10.

The illustrated motor mount assembly 200 includes shoulder pins 212, amotor plate 216, a motor plate bearing 220, an eccentric shaft 224, andan eccentric bearing 228. As shown in FIGS. 26 and 27 , the shoulderpins 212 are coupled to and extend from the axial face 204 of the motorcan 208. The illustrated shoulder pins 212 are threaded into the motorcan 208, but may alternatively be connected to the motor can 208 usingother suitable coupling means. In the illustrated embodiment, the motormount assembly 200 includes two shoulder pins 212 circumferentiallyspaced 180 degrees apart. In other embodiments, the motor mount assembly200 may include fewer or more shoulder pins that extend from the motorcan 208.

As shown in FIG. 28 , the motor plate 216 is an annular member thatincludes a relatively large central opening 232 (FIG. 29 ), a relativelysmall central opening 236, and two recesses 240 positioned ondiametrically opposite sides of the small central opening 236. Therelatively large central opening 232 is shaped and sized to receive themotor plate bearing 220. The relatively small central opening 236 fitsaround a boss 244 of the motor can 208 and provides clearance for ashaft 248 of the motor 14. The recesses 240 receive the shoulder pins212 to radially align the motor plate 216 on the motor can 208, as shownin FIG. 29 . The recesses 240 and the shoulder pins 212 also inhibitrelative rotation between the motor can 208 and the motor plate 216. Insome embodiments, the motor plate 216 may include fewer or morerecesses, depending on the number of shoulder pins extending from themotor can 208.

Referring back to FIG. 28 , the motor plate 216 also includes atolerance ring 252 coupled to an inner surface 256 of the motor plate216 that defines the relatively small central opening 236. In someembodiments, the tolerance ring 252 has a larger diameter than the smallcentral opening 236 such that the ring 252 is secured to the innersurface 256 of the motor plate 216 by its own resiliency. In otherembodiments, the tolerance ring 252 may be secured to the inner surface256 of the motor plate 216 using adhesives, fasteners, or other suitablecoupling means. The tolerance ring 252 includes a series of deformationor waves 260. The waves 260 engage the boss 244 of the motor can 208 andmay be deformed when the motor plate 216 is pressed onto the motor can208 to take up manufacturing tolerances between the motor plate 216 andthe motor can 208. When the motor plate 216 is fully installed on themotor can 208, the motor plate 216 is spaced slightly apart (e.g., nocloser than 0.5 mm (0.020 in.)) from the axial face 204 of the motor can208.

The motor plate 216 further includes two projections 264 formed ondiametrically opposite sides of the small central opening 236. Theillustrated projections 264 are circumferentially spaced 180 degreesapart and are evenly spaced between the recesses 240. The projections264 are captured between two clamshell portions 268A, 268B (FIG. 26 ) ofthe housing 12 when the housing 12 is assembled to inhibit rotation ofthe motor plate 216, and thereby the motor 14 relative to the housing12. In other embodiments, the motor plate 216 may include fewer or moreprojections that are engaged by the housing 12 to inhibit rotation ofthe motor plate 216 relative to the housing 12.

As shown in FIG. 30 , the motor plate bearing 220 is positioned withinthe relatively large central opening 232 of the motor plate 216 andsurrounds the motor shaft 248. The motor plate bearing 220 includes anouter race 272 that engages an inner surface 276 of the motor plate 216and an inner race 280 that engages an outer surface 284 of the eccentricshaft 224. The motor plate 216 helps concentrically align the motorplate bearing 220 with two motor shaft bearings positioned inside themotor can 208. When assembled within the central opening 232, the motorplate bearing 220 protrudes axially beyond an outer face 288 of themotor plate 216.

The eccentric shaft 224 is secured to the motor shaft 248 for rotationwith the motor shaft 248. As shown in FIG. 31 , the eccentric shaft 224includes a body portion 292 and an eccentric portion 296. The bodyportion 292 receives the motor shaft 248. The eccentric portion 296extends axially from the body portion 292 and supports the eccentricbearing 228. An aperture 300 is formed in the outer surface 284 of thebody portion 292 to help balance the eccentric shaft 224 duringrotation. The illustrated aperture 300 is a single, continuous slotformed in the body portion 292 by removing material from the bodyportion 292. In other embodiments, the aperture 300 may be a series ofdiscrete slots or holes formed in the body portion 292. The aperture 300balances the eccentric shaft 224 such that a separate counterweight doesnot need to be coupled to the motor shaft 248 or the eccentric shaft224. Furthermore, when the motor plate bearing 220 is positioned aroundthe body portion 292 of the eccentric shaft 224, the inner race 280 ofthe bearing 220 substantially covers the aperture 300 to inhibit greaseand other debris from filling the aperture 300.

Referring back to FIG. 30 , the eccentric bearing 228 is secured to theeccentric portion 296 of the eccentric shaft 224. In the illustratedembodiment, the eccentric bearing 228 is a spherical bearing. In otherembodiments, other suitable bearings may also or alternatively beemployed. The eccentric bearing 228 engages a fork 304 (FIG. 26 ) of thedrive mechanism 16 to convert rotatory motion of the motor 14 intooscillating motion.

In the illustrated embodiment, the motor plate bearing 220, theeccentric shaft 224, and the eccentric bearing 228 are preassembled as asingle unit before being installed on the motor shaft 248. Inparticular, the motor plate bearing 220, the eccentric shaft 224, andthe eccentric bearing 228 are press-fit together prior to being insertedinto the motor plate 216 and connected to the motor shaft 248. Such anarrangement facilitates assembling the motor mount assembly 200 on themotor 14 without having to independently install each of the components.

As shown in FIG. 26 , once assembled on the motor can 208, the motormount assembly 200 is connected to a gear case 308 of the drivemechanism 16 to mount the motor 14 within the housing 12 and connect themotor 14 to the drive mechanism 16. The motor plate bearing 220 engagesa washer 312 within the gear case 308 to axially align the motor 14 withthe gear case 308. Since the motor plate bearing 220 protrudes axiallybeyond the motor plate 216, the motor plate 216 itself does not contactthe washer 312. Instead, the motor plate bearing 220 takes up the spacebetween the motor plate 216 and the washer 312. As such, axial andradial loads act on the motor plate bearing 220 rather than on othercomponents of the motor mount assembly 200 or the motor 14.

The motor mount assembly 200 further includes an elastomeric member 316located at a distal end portion 320 of the motor 14 opposite from themotor plate 216. The illustrated elastomeric member 316 is a rubber bandthat surrounds the distal end portion 320 of the motor 14. Theelastomeric member 316 is engaged by an inwardly-protruding rib 324 ofthe housing 12 to support the distal end portion 320 of the motor 14.The elastomeric member 316 also helps dampen vibrations of the motor 14.

FIGS. 32-37 illustrate an accessory 350 for the power tool 10 accordingto one construction of the invention. The accessory 350 includes anattachment portion 354 that is configured to be attached to the housing12 of the power tool 10 and a tubular portion 358. The tubular portion358 is coupled to and extends from the attachment portion 354. A firstopening or passageway 362 (FIG. 34 ) extends from an inner surface 366of the attachment portion 354 through the tubular portion 358.

The attachment portion 354 includes a body 370 having a top surface 374,bottom surface 378 (FIG. 35 ), and the first, inner surface 366, whichis opposite a second, outer surface 382. The body 370 defines an axialopening 386 extending therethrough. The outer surface 382 includesprojections 390 that define a gripping surface.

The attachment portion 354 also includes teeth 394 that descend from thetop surface 374 and are coupled to the inner surface 366. Adjacent teeth394 are spaced apart from one another by a recess 398 therebetween. Eachtooth includes a body 402 having a bottom surface 406, a flange 410, anda recess 414 deposed between the bottom surface 406 and the flange 410.The body 402 of each tooth is spaced apart from the inner surface 366such that a gap 418 is created between the inner surface 366 and atleast a portion of the body 402 of each tooth 394. Additional oralternative constructions may include more or fewer teeth thanillustrated herein having any suitable configuration. The gap 418 isconfigured to receive a seal member therein, which will be discussed infurther detail below. The seal member 422 is removable and constructedfrom felt; other constructions may include seal members 422 having othercompressible, resilient materials. The seal member 422 includes adiscontinuity such that the seal member 422 does not obstruct thepassageway 362.

The accessory 350 includes an extension member 430 coupled to thetubular portion 358. The extension member 430 defines a secondpassageway 434. The first and second passageways 362, 434 are alignedwhen the extension member 430 is secured to the tubular portion 358. Theextension member 430 is configured to receive a vacuum hose (not shown).In the illustrated construction, the tubular portion 358 includes aprojection 438 extending from an exterior surface 442. The projection438 is received in an opening or aperture 446 extending through anexterior surface 450 of the extension member 430. Therefore, theextension member 430 may be coupled to the tubular portion 358 by asnap-fit engagement therebetween. The tubular portion 358 includes acircumferential rib 454 that abuts the extension member 430. In otherconstructions the extension member 430 and the tubular portion 358 maybe integrally molded or formed as one piece. In the illustratedconstruction, the extension member 430 is oriented at angle ZZ (FIG. 37) relative to the tubular portion 358; other constructions may have anangle ZZ that is greater or less than the angle illustrated herein.

The attachment portion 354 is coupled between a sanding pad 458 and thepower tool 10. The sanding pad 458 is secured to the blade clampmechanism 20 using the same process as described above with respect toFIGS. 1-25 . Sand paper 462 may be removably secured to a workingsurface of the sanding pad 458. In further constructions, the attachmentportion 354 may be used with other types of tools, as well.

During assembly, the attachment portion 354 is coupled to the housing 12of the power tool 10. In particular, the flanges 410 of the teeth 394are received in a circumferential groove 118 (FIG. 1 ) in the housing 12while a circumferential ridge 120 (FIGS. 1-3 ) portion of the housing 12is received in the recesses 414 of the teeth 394. As such, theattachment portion 354 is secured to the housing 12 by a snap-fitengagement therebetween. The extension member 430 may be secured to thetubular portion 358 before or after the attachment portion 354 issecured to the power tool 10. The sanding pad 458 is then secured to theclamping mechanism 20 as described above with respect to FIGS. 1-25 . Avacuum hose (not shown) is coupled to the extension member 430. Thecompressive and resilient properties of the seal create a better closurebetween the attachment portion 354 and the sanding pad 458.

During operation of the accessory 350 the sanding pad 458 oscillates asdescribed above in order to sand a working surface. Dust resulting fromthe sanding process accumulates between the sanding pad 458 and thepower tool 10 within the opening 386 of the accessory 350 and is thensucked through the first and second passageways 362, 434 by the suctionfunction of the vacuum. Because of the snap-fit engagement between theattachment portion 354 and the power tool 10, the attachment portion 354remains rotatable relative to the power tool 10 even after the sandingpad 458 is secured to the power tool 10. Therefore, the user may rotatethe attachment portion 354 about the output axis B of the power tool 10to position the vacuum hose in different positions about the power toolhousing 12 as necessary during the sanding process. The seal member 422ensures that a tight seal between the attached portion 354 and thesanding pad 458 is maintained, while still allowing the attachmentportion 354 to rotate without generating too much heat.

FIGS. 38-41 illustrate an accessory 550 according to anotherconstruction of the invention. The accessory of FIGS. 38-41 is similarto the accessory of FIGS. 32-37 ; therefore, like structure will beidentified by like reference numbers plus “200” and only the differenceswill be discussed hereafter.

The accessory 550 includes an attachment portion 554 that is configuredto be attached to the housing 12 of the power tool 10 in the same manneras the accessory 350 described above. The accessory 550 also includes atubular portion 558. The tubular portion 558 is attached to and extendsfrom the attachment portion 554. A first opening or passageway 562extends through the tubular portion 558 adjacent an outer surface 582 ofthe attachment portion 554. The attachment portion 554 is coupledbetween an output member 18 and the power tool 10. Blades, for example,typically create dust forward of the tool 10. Therefore, duringoperation of the accessory 550, dust resulting from the oscillation ofthe output element 18 is sucked through the passageway 562 in thetubular portion 558 by the suction function of the vacuum. Although notnecessarily illustrated with respect to FIGS. 38-41 it should beunderstood that the accessory 550 may include any or all of theadditional features discussed above with respect to FIGS. 32-37 (e.g.,projection on the outer surface 582 or a seal member between the innersurface 566 and the teeth 594).

FIGS. 42-44 illustrate an accessory 750 according to anotherconstruction of the invention. The accessory 750 includes an attachmentportion 754 that is configured to be attached to the housing 12 of thepower tool 10 in the same manner as the accessory 350 described above.

The attachment portion 754 includes a body 758 having a top surface 762,bottom surface 766, and a first, inner surface 770, which is opposite asecond, outer surface 774. The body 758 defines an axial opening 778extending therethrough. The outer surface 774 includes projections 782that define a gripping surface. The inner surface 770 includessubstantially evenly-spaced flanges or teeth 786. The inner surface 770may include more or fewer teeth than illustrated herein having anysuitable configuration.

The body 758 is substantially circular and additionally includes a firstend 790 and second end 794 with a gap 798 created therebetween. Thefirst end 790 includes a first projection 802 and the second end 794includes a second projection 806. The first and second projections 802,806 extend parallel to one another from the respective ends 794, 798 ofthe body 758. The first projection 802 includes a through-hole 812extending therebetween. The second projection 806 includes a closed-hole816 extending at least partially therethrough. The through-hole 812 andthe closed-hole 816 are aligned with one another and adapted to receivea fastener 820 (i.e., a screw) therethrough.

The body 758 further includes extension member 824 extending from theouter surface 774 of the body, opposite the first and second projections802, 806. The extension member 824 includes a substantially cylindricalportion 828 coupled to a substantially rectangular portion 832. Theextension member 824 defines a first through-hole 836 extending throughthe cylindrical portion 828. The first through-hole 836 is sized andshaped to slideably receive a tubular rod member 840. The rod member 840includes a stopper 844 at one end. In the illustrated construction, therod member 840 includes a substantially straight portion 848 coupled toa substantially serpentine or curved portion 852. Although notillustrated, it is contemplated that the straight portion 848 mayinclude measurement indicia on an outer surface thereof. The extensionmember 824 also includes a second through-hole 856 extending through therectangular portion 832 and into the cylindrical portion 828. The secondthrough-hole 856 is adapted to receive a fastener 860 (e.g., a setscrew). The first and second through-holes 836, 856 of the extensionmember 824 extend perpendicular to one another.

During assembly, the fastener 860 is removed in the direction of arrow864, which releases a clamping force on the rod member 840 therebyallowing it slide relative to the through-hole 836 in either directionof arrow 888. As such, the rod member 840 is positioned relative to theattachment portion, and therefore the housing the tool and the blade orwork piece. The rod member 840 is configured to extend beyond the blade.Once the rod member 840 is positioned to extend beyond the blade by adesired distance D1, the fastener 860 is advanced in a directionopposite the arrow 864, which restores the clamping force on the rodmember 840. The rod member 840 is also able to rotate within thethrough-hole 836 to position the stopper 844 and the curved portion 852in other positions relative to the blade.

Subsequently, the attachment portion 754 is coupled to the housing ofthe power tool. In particular, the teeth 786 are received in the groovein the housing. As such, the attachment portion 754 may be looselysecured and, therefore rotatable relative to, the housing such that theaccessory 750 may be positioned or adjusted appropriately relative tothe housing. That is, the accessory 750 may be rotated relative to thehousing to position the rod member 840 at angles other than theillustrated 180 degrees as appropriate for different work surfaces andtasks. After the attachment portion 754 has been adjusted, the fastener820 is advanced in the direction of arrow 892 into the closed-hole 816,which draws the first and second projections 802, 806. As the first andsecond projections 802, 806 are brought closer to one another, theattachment portion 754 tightens about the housing of the power toolthereby securing the accessory 750 to the power tool. Removal of thefastener 820 in a direction opposite arrow 892 allows the projections802, 806 to separate to loosen the attachment portion 754 and remove theaccessory 750 from the power tool. The output element 18 may be securedor removed as described above with respect to FIGS. 1-25 . Additionally,the accessory 750 may be positioned and secured to the housing of thepower tool prior to adjusting the rod member 840 to achieve a distanceD1

During operation, the rod member 840 extends beyond the blade, forexample, by the distance D1 to ensure that the blade only reaches adepth D1′ and nothing beyond D1′.

Thus, the invention provides, among other things, an oscillating multitool having a tapered tool holder for providing a substantiallyzero-clearance fit, a toolless blade change mechanism and a lever withdetent for operating the toolless blade change mechanism, an oscillatingmulti tool having an LED, an oscillating multi tool having an improvedmotor mount configuration and a balanced drive mechanism, and a compactconfiguration that does not interfere with the depth of cut. Theinvention also provides an adapter for adapting the tool holder to holdother types of output elements, the adapter having a substantiallyzero-clearance fit with both the tool holder and with output elements.The invention also provides snap-on accessories, such as a dustcollector and a depth guide. A group of accessories, such as a dustcollector and a depth guide, are attachable to the power tool by asnap-fit configuration. Each accessory in the group of accessoriesincludes the same mating interface for mating with the power tool suchthat the accessories are interchangeable. The snap-fit configurationallows the accessory to rotate with respect to the tool while theaccessory is attached to the tool.

Although the invention has been described with reference to certainpreferred embodiments, variations and modifications exist within thescope and spirit of one or more independent aspects of the invention.

What is claimed is:
 1. An oscillating power tool comprising: a housing;a motor disposed within the housing; a tool holder configured to bedriven oscillatingly about an output axis by the motor; a flangeconfigured to clamp an output element onto the tool holder, wherein theflange is configured to be movable in an axial direction defined by theoutput axis; a plunger operably coupled for movement with the flange inthe axial direction, wherein the plunger and the flange are threadedlycoupled to each other; and a lever configured to actuate the flange, thelever being pivotable between a clamping position and a releaseposition, wherein the flange is configured to clamp the output elementonto the tool holder in the clamping position, wherein the flange isconfigured to be displaced a first distance from the tool holder in therelease position, and wherein the lever includes a cam surface includinga substantially flat surface, the substantially flat surface configuredto engage the plunger in the release position, wherein in the releaseposition, a gap is disposed between the lever and the housing to allowthe lever to be rotated past the release position, and wherein the leveris configured to displace the flange a second distance from the toolholder when rotated past the release position, wherein the seconddistance is larger than the first distance.
 2. The oscillating powertool of claim 1, wherein the lever is pivotable about a pin, wherein thepin defines a pivot axis, wherein the pivot axis is substantiallyperpendicular to the output axis, and wherein the output axis intersectsthe pin.
 3. The oscillating power tool of claim 1, wherein the flangehas a threaded shaft extending therefrom, and wherein the plungerincludes a threaded bore for receiving the threaded shaft.
 4. Theoscillating power tool of claim 1, wherein the flange includes a tabconfigured for finger-tightening the flange.
 5. The oscillating powertool of claim 1, wherein the cam surface includes curved surfacesflanking the substantially flat surface.
 6. The oscillating power toolof claim 1, further comprising a spring configured to bias the flangetowards the tool holder.
 7. The oscillating power tool of claim 6,wherein the spring is operatively disposed between the tool holder andthe plunger.
 8. An oscillating power tool comprising: a housing; a motordisposed within the housing; a tool holder configured to be drivenoscillatingly about an output axis by the motor; a flange configured toclamp an output element onto the tool holder, wherein the flange isconfigured to be movable in an axial direction defined by the outputaxis; a spring configured to provide a clamping force for clamping theoutput element; a plunger operably coupled for movement with the flangein the axial direction; and a lever configured to actuate the flange,the lever being pivotable between a clamping position and a releaseposition, wherein the flange is configured to clamp the output elementonto the tool holder in the clamping position, wherein the flange isconfigured to be displaced a first distance from the tool holder in therelease position, wherein the clamping force is at least partiallyrelieved in the release position, and wherein the lever includes a camsurface including a substantially flat surface, the substantially flatsurface configured to engage the plunger in the release position,wherein the lever is configured to rest in the release position, whereinin the release position, a gap is disposed between the lever and thehousing to allow the lever to be rotated past the release position, andwherein the lever is configured to further relieve the clamping forcewhen rotated past the release position.
 9. The oscillating power tool ofclaim 8, wherein the spring is operatively disposed between the toolholder and the plunger.
 10. The oscillating power tool of claim 8,wherein the spring is configured to bias the plunger towards the camsurface.
 11. The oscillating power tool of claim 8, wherein the lever isconfigured to compress the spring by way of movement of the levertowards the release position and to further compress the spring by wayof movement of the lever past the release position.
 12. The oscillatingpower tool of claim 8, wherein the lever is pivotable about a pindefining a pivot axis, wherein the pivot axis is substantiallyperpendicular to the output axis, and wherein the output axis intersectsthe pin.
 13. The oscillating power tool of claim 8, wherein the flangehas a threaded shaft extending therefrom, and wherein the plungerincludes a threaded bore for receiving the threaded shaft.
 14. Theoscillating power tool of claim 13, wherein the flange includes a tabconfigured for finger-tightening the flange.
 15. The oscillating powertool of claim 8, wherein the cam surface includes curved surfacesflanking the substantially flat surface.
 16. An oscillating power toolcomprising: a housing; a motor disposed within the housing; a toolholder configured to be driven oscillatingly about an output axis by themotor; a flange configured to clamp an output element onto the toolholder, wherein the flange is configured to be movable in an axialdirection defined by the output axis; a spring configured to provide aclamping force for clamping the output element; a plunger operablycoupled for movement with the flange in the axial direction; and a leverconfigured to actuate the flange, the lever being pivotable between aclamping position and a release position, wherein the flange isconfigured to clamp the output element onto the tool holder in theclamping position, wherein the flange is configured to be displaced afirst distance from the tool holder in the release position, wherein theclamping force is at least partially relieved in the release position,and wherein the lever includes a cam surface defining a detent such thatthe lever is configured to rest in the release position by way of thedetent, wherein in the release position, a gap is disposed between thelever and the housing to allow the lever to be rotated past the releaseposition, and wherein the lever is configured to further relieve theclamping force when rotated past the release position.
 17. Theoscillating power tool of claim 16, wherein the lever is configured tocompress the spring by way of movement of the lever towards the releaseposition and to further compress the spring by way of movement of thelever past the release position.
 18. The oscillating power tool of claim16, wherein the flange has a threaded shaft extending therefrom, andwherein the plunger includes a threaded bore for receiving the threadedshaft.
 19. The oscillating power tool of claim 18, wherein the flangeincludes a tab configured for finger-tightening the flange.
 20. Theoscillating power tool of claim 16, wherein the spring is configured tobias the plunger towards the cam surface.